Poke-in wire connector for power connector assembly

ABSTRACT

A poke-in terminal includes a main body, a tab terminal socket at a mating end, and a wire socket at a terminating end. The tab terminal socket includes walls forming a tab terminal receptacle configured to receive a tab terminal. Upper and lower beam contacts extend into the tab terminal receptacle to interface with the tab terminal. The wire socket includes walls forming a wire receptacle configured to receive a wire. Poke-in retention beams extend into the wire receptacle to interface with the wire when poked into the wire socket. The wire socket includes a wire release element configured to be actuated to release the poke-in retention beams from the wire.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of, and claims priorityto U.S. application Ser. No. 17/005,506, filed 28 Aug. 2020, titled“POKE-IN WIRE CONNECTOR FOR POWER CONNECTOR ASSEMBLY”, the subjectmatter of which are herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to electrical connectors forelectrical devices.

Cables are electrically connected to electrical devices by terminatingwires to terminals within the electrical devices. For example, thecables may be power cables having power wires, such as a hot wire, aneutral wire, and a ground wire, which are electrically connected towires or terminals of the electrical device. The wires are typicallyterminated to device wires of the electrical device using wire nuts. Thewires may be terminated to device terminals of the electrical deviceusing contacts crimped to the wires. Conventional terminations may beunreliable, particularly when novice installers, such as homeowners,perform the terminations. Additionally, access to the device terminalsor device wires is typically limited, making termination of the wires tothe device wires or the device terminals difficult.

A need remains for electrical connectors that may be reliably coupled toelectrical devices.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a poke-in terminal is provided. The poke-in terminalincludes a main body extending between a mating end and a terminatingend of the poke-in terminal. The poke-in terminal includes a tabterminal socket at the mating end. The tab terminal socket includeswalls forming a tab terminal receptacle configured to receive a tabterminal. The tab terminal socket includes upper beam contacts extendingfrom a top wall into the tab terminal receptacle to interface with thetab terminal and lower beam contacts extending from a bottom wall intothe tab terminal receptacle to interface with the tab terminal. Thepoke-in terminal includes a wire socket at the terminating end. The wiresocket includes walls forming a wire receptacle configured to receive awire. The wire socket includes a first poke-in retention beam configuredto interface with the wire when poked into the wire socket and a secondpoke-in retention beam configured to interface with the wire when pokedinto the wire socket. The wire socket includes a wire release elementconfigured to be actuated to release the first and second poke-inretention beams from the wire.

In another embodiment, a poke-in wire connector provides a housingincluding a top housing wall, a bottom housing wall, a first housingside wall, and a second housing side wall. The housing includes terminalcavities extending between a front and a rear of the housing. Thehousing includes separating walls between the terminal cavities. Thepoke-in terminal includes a plurality of poke-in terminals received incorresponding terminal cavities. Each poke-in terminal includes a mainbody extending between a mating end and a terminating end, a tabterminal socket at the mating end, and a wire socket at the terminatingend. The tab terminal socket is provided at the front of the housing forreceiving a corresponding tab terminal. The tab terminal socketincluding a top wall, a bottom wall, a first side wall, and a secondside wall forming a tab terminal receptacle configured to receive thecorresponding tab terminal. The tab terminal receptacle is rectangularshaped. The tab terminal socket includes upper beam contacts extendingfrom the top wall into the tab terminal receptacle to interface with thetab terminal and lower beam contacts extending from the bottom wall intothe tab terminal receptacle to interface with the tab terminal. The wiresocket is provided at the rear of the housing for receiving acorresponding wire during a poke-in process. The wire socket includeswalls forming a wire receptacle configured to receive the correspondingwire. The wire socket includes a first poke-in retention beam configuredto interface with the wire when poked into the wire socket and a secondpoke-in retention beam configured to interface with the wire when pokedinto the wire socket. The wire socket includes a wire release elementconfigured to be actuated to release the first and second poke-inretention beams from the wire.

In a further embodiment, an electrical connector assembly is provided.The electrical connector assembly includes a cover plate including amounting flange configured to be mounted to a device housing of anelectrical device. The cover plate includes an opening. The electricalconnector assembly includes a strain relief device coupled to the coverplate at the opening of the cover plate. The strain relief deviceincludes a bore therethrough configured to receive a power cableincluding a plurality of power wires including a ground wire, a hot wireand a neutral wire. The strain relief device provides strain relief forthe power cable. The electrical connector assembly includes a poke-inwire connector coupled to the cover plate. The poke-in wire connectorincludes a housing having terminal cavities and poke-in terminalsreceived in corresponding terminal cavities. The poke-in terminals areconfigured to be electrically connected to the ground wire, the hot wireand the neutral wire. The housing includes a top housing wall, a bottomhousing wall, a first housing side wall, and a second housing side wall.The terminal cavities extend between a front and a rear of the housing.The housing includes separating walls between the terminal cavities.Each poke-in terminal includes a main body extending between a matingend and a terminating end, a tab terminal socket at the mating end, anda wire socket at the terminating end. The tab terminal socket providedat the front of the housing receives a corresponding tab terminal of theelectrical device. The tab terminal socket includes a top wall, a bottomwall, a first side wall, and a second side wall forming a tab terminalreceptacle configured to receive the corresponding tab terminal. The tabterminal socket includes upper beam contacts extending from the top wallinto the tab terminal receptacle to interface with the tab terminal andlower beam contacts extending from the bottom wall into the tab terminalreceptacle to interface with the tab terminal. The wire socket isprovided at the rear of the housing for receiving a corresponding powerwire during a poke-in process. The wire socket includes walls forming awire receptacle configured to receive the corresponding power wire. Thewire socket includes a first poke-in retention beam configured tointerface with the power wire when poked into the wire socket and asecond poke-in retention beam configured to interface with the powerwire when poked into the wire socket, the wire socket including a wirerelease element configured to be actuated to release the first andsecond poke-in retention beams from the power wire.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an electrical device having anelectrical connector assembly in accordance with an exemplaryembodiment.

FIG. 2 is a bottom perspective view of a portion of the electricaldevice illustrating the electrical connector assembly coupled to adevice housing of the electrical device in accordance with an exemplaryembodiment.

FIG. 3 is a perspective view of the electrical connector assembly inaccordance with an exemplary embodiment.

FIG. 4 is a top perspective view of the electrical connector assembly inaccordance with an exemplary embodiment.

FIG. 5 illustrates a portion of a poke-in wire connector of theelectrical connector assembly showing poke-in terminals terminated toends of wires of a power cable in accordance with an exemplaryembodiment.

FIG. 6 is a top, rear perspective view of the poke-in terminal inaccordance with an exemplary embodiment.

FIG. 7 is a rear end view of the poke-in terminal in accordance with anexemplary embodiment.

FIG. 8 is a bottom, front perspective view of the poke-in terminal inaccordance with an exemplary embodiment.

FIG. 9 illustrates the electrical connector assembly in a partiallyassembled state in accordance with an exemplary embodiment.

FIG. 10 illustrates the electrical connector assembly in a partiallyassembled state in accordance with an exemplary embodiment.

FIG. 11 illustrates a portion of the electrical connector assemblyshowing the poke-in wire connector coupled to the power cable inaccordance with an exemplary embodiment.

FIG. 12 is a perspective view of a portion of the electrical connectorassembly showing the poke-in wire connector coupled to the power cablein accordance with an exemplary embodiment.

FIG. 13 illustrates the electrical connector assembly showing thepoke-in wire connector poised for coupling to a cover plate inaccordance with an exemplary embodiment.

FIG. 14 illustrates the electrical connector assembly showing thepoke-in wire connector coupled to the cover plate in accordance with anexemplary embodiment.

FIG. 15 illustrates the electrical connector assembly poised forcoupling to the electrical device in accordance with an exemplaryembodiment.

FIG. 16 illustrates the electrical connector assembly partially coupledto the electrical device in accordance with an exemplary embodiment.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic illustration of an electrical device 10 having anelectrical connector assembly 100 in accordance with an exemplaryembodiment. In various embodiments, the electrical connector assembly100 may be a power connector assembly used to supply power to theelectrical device 10. In other various embodiments, the electricalconnector assembly 100 may be a data connector used to transmit databetween the electrical device 10 and another component. In variousembodiments, the electrical device 10 may be an appliance, such as ahome appliance. The electrical device 10 includes one or more poweredcomponents 12 that receive power from the electrical connector assembly100. For example, the power components 12 may include motors, pumps,compressors, or other types of powered components.

The electrical device 10 includes a device housing 14 that surrounds thepowered components 12. The device housing 14 includes one or more walls16 forming a cavity 18 that houses the powered components of 12. Theelectrical connector assembly 100 may be mounted to one of the walls 16,such as a bottom wall of the device housing 14. In an exemplaryembodiment, the electrical device 10 includes one or more tab terminals20 within the cavity 18. The tab terminals 20 may be blade terminals,male terminals or quick disconnect terminals, such as FASTON terminals.In various embodiments, the terminals 20 are 187 series FASTON terminalshaving a width of 0.187 inches. Other types of terminals may be used inalternative embodiments, such as pin terminals, socket terminals, andthe like. The terminals 20 may be terminated to a wire, circuit board orother electrical component of the electrical device 10. The electricalconnector assembly 100 is coupled to the tab terminals 20. In anexemplary embodiment, the electrical connector assembly 100 is coupledto the tab terminals 20 at a separable interface. In an exemplaryembodiment, the electrical device 10 includes three tab terminals 20,such as a ground tab terminal, a line or hot tab terminal, and a neutraltab terminal. Other types of tab terminals 20 may be provided inalternative embodiments.

FIG. 2 is a bottom perspective view of a portion of the electricaldevice 10 illustrating the electrical connector assembly 100 coupled tothe device housing 14 of the electrical device 10. In an exemplaryembodiment, the device housing 14 includes an opening 22 through thewall 16 that receives the electrical connector assembly 100. Theelectrical connector assembly 100 may be mounted to the device housing14 from the exterior of the electrical device 10 (for example, withoutopening or accessing the interior of the device housing 14). As such,the electrical connector assembly 100 may be field installed to thedevice housing 14, such as without the need for specialized tooling andwithout the need for disassembly of the electrical device 10.

The electrical connector assembly 100 includes a cover plate 102 and astrain relief device 104 coupled to the cover plate 102. The cover plate102 is coupled to the device housing 14 using one or more fasteners 24.The electrical connector assembly 100 includes a poke-in wire connector200 coupled to the cover plate 102. The poke-in wire connector 200 isconfigured to be electrically connected directly to the tab terminals 20(shown in FIG. 1 ) of the electrical device 10. A power cable 106extends through the cover plate 102 for electrical connection to thepoke-in wire connector 200. The strain relief device 104 provide strainrelief for the power cable 106. The strain relief device 104 may be usedto mechanically coupled the power cable 106 to the cover plate 102. Inan exemplary embodiment, the power cable 106 includes a conduit 108,such as a metal conduit, that surrounds and protects the power cable106. In various embodiments, the power cable 106 is building wiringhaving two or three power wires providing single phase electrical powerto the electrical device 10. For example, the power cable 106 mayinclude a hot wire 110, a neutral wire 112, and a ground wire 114.

FIG. 3 is a perspective view of the electrical connector assembly 100 inaccordance with an exemplary embodiment. FIG. 4 is a top perspectiveview of the electrical connector assembly 100 in accordance with anexemplary embodiment. The electrical connector assembly 100 includes thecover plate 102, the strain relief device 104, and the poke-in wireconnector 200. The poke-in wire connector 200 is coupled to the coverplate 102. The wires 110, 112, 114 of the power cable 106 areelectrically connected to the poke-in wire connector 200. For example,ends of the wires 110, 112, 114 are configured to be poked into thepoke-in wire connector 200 for electrical termination to correspondingcontacts of the poke-in wire connector 200. The strain relief device 104holds the power cable 106 relative to the cover plate 102.

The strain relief device 104 includes a hub 120 having a bore 122therethrough. The strain relief device 104 includes a nut 124 used tosecure the hub 120 to the cover plate 102. The strain relief device 104includes a clamp 126 used to secure the power cable 106 to the hub 120and the cover plate 102. The clamp 126 may be tightened around theconduit 108 holding the power cable 106 using fasteners 128. Optionally,the clamp 126 may be a two-piece clamp having a right half and a lefthalf secured together using fasteners 128. The fasteners 128 aretightened to secure the clamp 126 around the hub 120. In an exemplaryembodiment, the hub 120 extends through an opening 130 in the coverplate 102. A portion of the hub 120 is located interior of the coverplate 102 and a portion of the hub 120 is located exterior of the coverplate 102. For example, the clamp 126 is coupled to the exterior portionof the hub 120 and the nut 124 is coupled to the interior portion of thehub 120. In an exemplary embodiment, the hub 120 is threaded andincludes threads 132 along the interior portion. The nut 124 isthreadably coupled to the threads 132. The power cable 106 extendsthrough the bore 122 into the interior of the electrical connectorassembly 100 for termination to the poke-in wire connector 200.

The cover plate 102 includes a mounting plate 140. The mounting plate140 is configured to be coupled to the device housing 14 (shown in FIG.2 ). In an exemplary embodiment, the poke-in wire connector 200 iscoupled to the mounting plate 140. In an exemplary embodiment, the coverplate 102 includes a well 142 extending downward from the mounting plate140. The well 142 forms a space 144 that receives the strain reliefdevice 104. For example, the interior portion of the hub 120 and the nut124 are received in the well 142. The opening 130 is provided in abottom wall 146 of the well 142. The cover plate 102 may have othershapes in alternative embodiments.

The poke-in wire connector 200 includes a housing 202 holding aplurality of poke-in terminals 300 (shown in FIG. 5 ). The housing 202is manufactured from a dielectric material, such as a plastic material.The housing 202 may be manufactured during a molding process, such asbeing injection molded. The housing 202 extends between a mating end 204and a wire end 206. The wires 110, 112, 114 extend from the wire end206. In various embodiments, the wire end 206 may be generally oppositethe mating end 204. For example, the mating end 204 may be provided at afront 205 of the housing 202 and the wire end 206 may be provided at arear 207 of the housing 202. In alternative embodiments, the housing 202may be a right-angle housing having the mating end 204 perpendicular tothe wire end 206.

The housing 202 includes a top housing wall 210, a bottom housing wall212, a first housing side wall 214, and a second housing side wall 216.In an exemplary embodiment, the housing 202 includes separating walls218 extending between the top housing wall 210 and the bottom housingwall 212. The separating walls 218 extend between the mating end 204 andthe wire end 206 to form cavities 220 that receive corresponding poke-interminals 300. The separating walls 218 electrically isolate the poke-interminals 300. The separating walls 218 may be oriented generallyparallel to the first and second housing side walls 214, 216. In variousembodiments, front and rear ends of the separating walls 218 may bechamfered to provide a lead-in surfaces for loading the wires 110, 112,114 into the cavities 220 and/or to guide the tab terminals 20 (shown inFIG. 1 ) into the cavities 220.

In an exemplary embodiment, the housing 202 includes a platform 222 atthe rear 207 of the housing 202. The platform 222 supports the wires110, 112, 114 rearward of the cavities 220. The platform 222 may bedefined by a rear portion of the bottom housing wall 212. Portions ofthe first and second housing side walls 214, 216 may extend along theplatform 222 two contain the wires 110, 112, 114. The platform 222provides access to the cavities 220.

In an exemplary embodiment, the housing 202 includes pockets 224 at thefront 205 of the housing 202. The pockets 224 receive mounting tabs 148of the cover plate 102. The mounting tabs 148 are used to locate andsecure the poke-in wire connector 200 to the cover plate 102. Themounting tabs 148 may extend from the front of the mounting plate 140.In the illustrated embodiment, the mounting tabs 148 are bent or foldedover to form hooks that extend into the pockets 224 of the housing 202to secure the housing 202 to the cover plate 102. In an exemplaryembodiment, the housing 202 includes latches 226 used to secure thehousing 202 to the cover plate 102. In the illustrated embodiment, thelatches 226 are provided at the first and second housing side walls 214,216. The latches 226 are provided proximate to the front 205. Thelatches 226 may be deflectable relative to the housing 202 to latchablycouple the housing 202 to the cover plate 102. In an exemplaryembodiment, each latch 226 includes a blocking surface 228 configured toengage the cover plate 102 and retain the housing 202 on the cover plate102. For example, the blocking surface 228 may prevent rearward movementof the housing 202 relative to the cover plate 102.

In an exemplary embodiment, the housing 202 includes guide pins 230 usedto guide mating of the poke-in wire connector 200 to the device housing14 of the electrical device 10 (shown in FIG. 2 ). In the illustratedembodiment, the guide pins 230 are provided at the first and secondhousing side walls 214, 216. The guide pins 230 are locatedapproximately centered between the front 205 and the rear 207. The guidepins 230 may be provided at other locations in alternative embodiments.In an exemplary embodiment, the guide pins 230 have a curved outersurface (for example, semi-cylindrical shaped). However, the guide pins230 may have other shapes in alternative embodiments. Optionally, topends of the guide pins 230 may include lead-in surfaces 232. Forexample, the top end of the guide pins 230 may be cone shaped. The leadin surfaces 232 guide mating of the guide pins 230 with the devicehousing 14.

In an exemplary embodiment, the housing 202 includes release openings240 in the top housing wall 210. The release openings 240 provide accessto the poke-in terminals 300. The release openings 240 are configured toreceive a released tool used to release the wires 110, 112, 114 from thepoke-in terminals 300. For example, a screwdriver or other tool may bepushed into the cavities 220 to interface with the poke-in terminals 300and release the wires 110, 112, 114 from the poke-in terminals 300.

FIG. 5 illustrates a portion of the poke-in wire connector 200 showingthe poke-in terminals 300 terminated to ends of the wires 110, 112, 114of the power cable 106. The ends of the wires 110, 112, 114 areconfigured to be poked into the poke-in terminals 300 to make a quickand reliable electrical connection between the poke-in terminals 300 andthe wires 110, 112, 114. In an exemplary embodiment, the terminationbetween the wires 110, 112, 114 and the poke-in terminals 300 is aseparable termination allowing the wires 110, 112, 114 to be releasedfrom the poke-in terminals 300, such as for repair/replacement of thepower cable 106 or repair/replacement of the poke-in wire connector 200.

Each wire 110, 112, 114 includes a conductor 116 and an insulator 118surrounding the conductor 116. The end of the insulator 118 may beremoved to expose the end of the conductor 116. The end of the conductor116 is configured to be poked into the corresponding poke-in terminal300. Optionally, the wires 110, 112, 114 may be bundled together withina cable jacket (not shown).

In the illustrated embodiment, the power cable 106 includes the threewires, namely the hot wire 110, the neutral wire 112, and the groundwire 114. Three of the poke-in terminals 300 are similarly provided andterminated to the corresponding wires 110, 112, 114. The poke-interminals 300 are configured to be received in the housing 202 (shown inFIGS. 3 and 4 ). In an exemplary embodiment, the poke-in terminals 300are located in the housing 202 prior to the wires 110, 112, 114 beingterminated to the poke-in terminals 300. Optionally, the poke-interminals 300 may be identical; however, the poke-in terminals 300 mayhave different features in alternative embodiments.

FIG. 6 is a top, rear perspective view of the poke-in terminal 300 inaccordance with an exemplary embodiment. FIG. 7 is a rear end view ofthe poke-in terminal 300 in accordance with an exemplary embodiment.FIG. 8 is a bottom, front perspective view of the poke-in terminal 300in accordance with an exemplary embodiment.

In an exemplary embodiment, the poke-in terminal 300 is manufacturedfrom a metal material, such as copper, aluminum, stainless steel, andthe like. The poke-in terminal 300 may be stamped and formed from ametal sheet. For example, features of the poke-in terminal 300 may bestamped from the metal sheet and then the features are bent into apredetermined shape. The poke-in terminal 300 includes a main body 302extending between a mating end 304 and a terminating end 306 of thepoke-in terminal 300. Optionally, the mating end 304 may be opposite theterminating end 306. For example, the mating end 304 may be provided ata front of the poke-in terminal 300 and the terminating end 306 may beprovided at a rear of the poke-in terminal 300. In alternativeembodiments, the poke-in terminal 300 may be a right-angle terminalhaving the mating end 304 perpendicular to the terminating end 306. Themating end 304 and the terminating end 306 may be at other (non-paralleland non-perpendicular) orientations in alternative embodiments. Thepoke-in terminal 300 includes a tab terminal socket 320 at the matingend 304 and a wire socket 350 at the terminating end 306. The tabterminal socket 320 is configured to receive one of the tab terminals 20(shown in FIG. 1 ) during a mating process with the electrical device10. The wire socket 350 is configured to receive one of the wires 110,112, 114 (shown in FIG. 5 ) during a wire poke-in process.

The main body 302 includes a bottom plate 310 and side walls 312, 314extending from the bottom plate 310. The side walls 312, 314 providerigidity and structural strength to the main body 302 of the poke-interminal 300. Optionally, the bottom plate 310 and the side walls 312,314 may be flared outward between the wire socket 350 in the tabterminal socket 320. In an exemplary embodiment, the main body 302includes a stop feature 316 forward of the wire socket 350. The stopfeature 316 is used to stop loading of the wire 110, 112, 114 into thewire socket 350 to position the wire 110, 112, 114 in the wire socket350. In the illustrated embodiment, the stop feature 316 is stamped fromthe bottom plate 310 and bent upward such that the stop feature 316 ispositioned forward of the wire socket 350. In the illustratedembodiment, the top of the main body 302 is open between the side walls312, 314. However, in alternative embodiments, the main body 302 mayinclude a top wall extending between the side walls 312, 314.

The tab terminal socket 320 is provided at the mating end 304 for matingwith the tab terminal 20. The tab terminal socket 320 includes aplurality of walls, such as four walls forming a tab terminal receptacle330. In the illustrated embodiment, the plurality of walls includes afirst or top wall 322, a second or bottom wall 324, a third or firstside wall 326, and a fourth or second side wall 328 forming the tabterminal receptacle 330. The tab terminal socket 320 may be oriented inother orientations such that any of the other walls 324, 326, 328 maydefine a top wall or none of the walls may be a top wall (for example,the tab terminal receptacle 330 may be open at a top of the tab terminalsocket 320). The tab terminal receptacle 330 receives the tab terminal20. The bottom wall 324 may be generally co-planer with the bottom plate310 of the main body 302. The first and second side walls 326, 328transition into the side walls 312, 314 of the main body 302.Optionally, the first and second side walls 326, 328 may be taller thanthe side walls 312, 314. The walls 322, 324, 326, 328 of the tabterminal socket 320 surrounds the tab terminal receptacle 330 on foursides. The tab terminal receptacle 330 is sized and shaped to receivethe tab terminal 20. For example, the tab terminal receptacle 330 may berectangular shaped having a width approximately equal to the width ofthe tab terminal 20 and a height approximately equal to the height ofthe tab terminal 20. In the illustrated embodiment, the tab terminalreceptacle 330 is short and wide having a width greater than a heightthereof. In various embodiments, the width of the tab terminalreceptacle 330 may be at least twice the height of the tab terminalreceptacle 330.

The tab terminal socket 320 includes upper beam contacts 332 extendingfrom the top wall 322 into the tab terminal receptacle 330 to interfacewith the tab terminal 20. In the illustrated embodiment, the tabterminal socket 320 includes a pair of the upper beam contacts 332;however, the tab terminal socket 320 may include greater or fewer upperbeam contacts 332 in alternative embodiments. The tab terminal socket320 includes lower beam contacts 334 extending from the bottom wall 324into the tab terminal receptacle 330 to interface with the tab terminal20. In the illustrated embodiment, the tab terminal socket 320 includesa pair of the lower beam contacts 334; however, the tab terminal socket320 may include greater or fewer lower beam contacts 334 in alternativeembodiments. In an exemplary embodiment, the upper and lower beamcontacts 332, 334 are cantilevered beams angled inward into the tabterminal receptacle 330 to interface with the tab terminal 20.Optionally, the upper and lower beam contacts 332, 334 are fixed atforward ends of the upper and lower beam contacts 332, 334 such that theupper and lower beam contacts 332, 334 extend rearwardly into the tabterminal receptacle 330. The upper and lower beam contacts 332, 334 havemating interfaces proximate to distal ends of the upper and lower beamcontacts 332, 334. Optionally, the mating interfaces may be aligned witheach other on opposite sides of the tab terminal receptacle 330.Alternatively, the mating interfaces may be offset relative to eachother, which may reduce tab insertion forces into the tab terminalsocket 320. The upper and lower beam contacts 332, 334 are deflectablewhen mated with the tab terminal 20. For example, the upper and lowerbeam contacts 332, 334 may be deflected in an outward direction (forexample, the upper beam contacts 332 are deflected upward and the lowerbeam contacts 334 are deflected downward). The plurality of upper andlower beam contacts 332, 334 provide multiple points of contact betweenthe tab terminal socket 320 and the tab terminal 20.

The wire socket 350 is provided at the terminating end 306. The wiresocket 350 includes a plurality of walls, such as four walls, forming awire receptacle 360. In the illustrated embodiment, the wire socket 350includes a first or top wall 352, a second or bottom wall 354, a thirdor first side wall 356, and fourth or a second side wall 358 forming awire receptacle 360 configured to receive the corresponding power wire110, 112, 114. The wire socket 350 may be oriented in other orientationssuch that any of the other walls 354, 356, 358 may define a top wall ornone of the walls may be a top wall (for example, the wire receptacle360 may be open at a top of the wire socket 350). In the illustratedorientation, the bottom wall 354 transitions from the bottom plate 310of the main body 302. Optionally, the bottom wall 354 may be generallycoplanar with the bottom plate 310. Alternatively, the bottom wall 354may transition downward relative to the bottom plate 310 such that thebottom wall 354 is located below the bottom plate 310. The first andsecond side walls 356, 358 transition into the side walls 312, 314 ofthe main body 302. Optionally, the first and second side walls 356, 358may be taller than the side walls 312, 314.

The wire receptacle 360 is sized and shaped to receive the correspondingpower wire 110, 112, 114. For example, the wire receptacle 360 may besquare shaped having a width and a height approximately equal to, orslightly wider than, a diameter of the wire 110, 112, 114 to center thewire 110, 112, 114 in the wire receptacle 360. In the illustratedembodiment, the wire receptacle 360 is taller than the tab terminalreceptacle 330 while the tab terminal receptacle 330 is wider than thewire receptacle 360. In an exemplary embodiment, the wire socket 350includes a front box 362 and a rear box 364 rearward of the front box362. The rear box 364 is spaced apart from the front box 362. The frontbox 362 is defined by the walls 352, 354, 356, 358. The front box 362surrounds the wire receptacle 360 on four sides. The rear box 364 isdefined by the walls 352, 354, 356, 358. The rear box 364 surrounds thewire receptacle 360 on four sides.

The wire socket 350 includes a first poke-in retention beam 366configured to interface with the power wire 110, 112, 114 when pokedinto the wire socket 350. The first poke-in retention beam 366 isprovided at the first side wall 356. The first poke-in retention beam366 is located between the front box 362 and the rear box 364. In theillustrated embodiment, the first poke-in retention beam 366 extendsfrom the rear box 364 toward the front box 362. The first poke-inretention beam 366 is angled inward into the wire receptacle 360 tointerface with the power wire 110, 112, 114. The wire socket 350includes a second poke-in retention beam 368 configured to interfacewith the power wire 110, 112, 114 when poked into the wire socket 350.The second poke-in retention beam 368 is provided at the second sidewall 358. The second poke-in retention beam 368 is located between thefront box 362 and the rear box 364. In the illustrated embodiment, thesecond poke-in retention beam 368 extends from the rear box 364 towardthe front box 362. The second poke-in retention beam 368 is angledinward into the wire receptacle 360 to interface with the power wire110, 112, 114. The wire socket 350 may include greater or fewer poke-inretention beams in alternative embodiments.

In an exemplary embodiment, the first and second poke-in retention beams366, 368 are cantilevered beams angled inward into the wire receptacle360 to interface with the corresponding wire 110, 112, 114. Optionally,the first and second poke-in retention beams 366, 368 are fixed at rearends of the first and second poke-in retention beams 366, 368 such thatthe first and second poke-in retention beams 366, 368 extend forwardlyinto the wire receptacle 360. The first and second poke-in retentionbeams 366, 368 have edges 370, 372, respectively, at distal ends of thefirst and second poke-in retention beams 366, 368 configured to retainthe wire 110, 112, 114 in the wire socket 350. For example, the edges370, 372 may dig into the wire 110, 112, 114 to resist pullout of thewire 110, 112, 114 from the wire socket 350. Optionally, the edges 370,372 may be aligned with each other on opposite sides of the wirereceptacle 360 to pinch the wire 110, 112, 114 therebetween.Alternatively, the edges 370, 372 may be offset relative to each otherand force the wire 110, 112, 114 to bend or kink around the first andsecond poke-in retention beams 366, 368, which may increase theretention force to hold the wire 110, 112, 114 in the wire socket 350.The first and second poke-in retention beams 366, 368 are deflectablewhen mated with the wire 110, 112, 114. For example, the first andsecond poke-in retention beams 366, 368 may be deflected in an outwarddirection. The first and second poke-in retention beams 366, 368 providemultiple points of contact between the wire socket 350 and thecorresponding wire 110, 112, 114.

The wire socket 350 includes a wire release element 380 configured to beactuated to release the first and second poke-in retention beams 366,368 from the power wire 110, 112, 114. For example, the wire releaseelement 380 may be pressed downward into the wire receptacle 360 toforce the first and second poke-in retention beams 366, 368 outward awayfrom the power wire 110, 112, 114. The wire release element 380 islocated between the front box 362 and the rear box 364. In an exemplaryembodiment, the wire release element 380 is a cantilevered beam angledinward into the wire receptacle 360 to interface with the first andsecond poke-in retention beams 366, 368. Optionally, the wire releaseelement 380 is fixed at the rear end thereof and extends forwardly intothe wire receptacle 360. In the illustrated embodiment, the wire releaseelement 380 is provided along the top wall 352 of the wire socket 350.The wire release element 380 is deflectable into the wire receptacle 360to interface with the first and second poke-in retention beams 366, 368.

In an exemplary embodiment, the wire release element 380 includes a mainbeam 382 extending from the rear box 364 to a free end 384. The wirerelease element 380 includes a first deflecting tab 386 extending fromthe main beam 382 at the free end 384 to engage the first poke-inretention beam 366. The wire release element 380 includes a seconddeflecting tab 388 extending from the main beam 382 at the free end 384to engage the second poke-in retention beam 368. The first and seconddeflecting tabs 386, 388 are flared upward nonparallel to the main beam382 to interface with and deflect the first and second poke-in retentionbeams 366, 368 outward as the wire release element 380 is actuated.

FIG. 9 illustrates the electrical connector assembly 100 in a partiallyassembled state. FIG. 10 illustrates the electrical connector assembly100 in a partially assembled state. FIG. 9 illustrates the poke-in wireconnector 200 poised for coupling with the power cable 106. FIG. 10illustrates the poke-in wire connector 200 coupled to the power cable106.

During assembly, the poke-in terminals 300 (shown in FIG. 6 ) arereceived in the housing 202. The individual wires 110, 112, 114 may bepoked into the poke-in wire connector 200 to electrically connect to thecorresponding poke-in terminals 300. Optionally, the cover plate 102 andthe strain relief device 104 may be loosely coupled to the power cable106 (for example, loosely coupled to the conduit 108) to allow a usablelength of the power cable 106 to be pulled through the cover plate 102and the strain relief device 104 for termination to the poke-in wireconnector 200. After the wires one, 112, 114 are poked into the poke-interminals 300 in the housing 202, the poke-in wire connector 200 may becoupled to the cover plate 102.

FIG. 11 illustrates a portion of the electrical connector assembly 100showing the poke-in wire connector 200 coupled to the power cable 106.FIG. 12 is a perspective view of a portion of the electrical connectorassembly 100 showing the poke-in wire connector 200 coupled to the powercable 106. When assembled, the poke-in terminals 300 are received incorresponding cavities 220 of the housing 202. The release openings 240in the housing 202 are aligned with the wire release elements 380 (shownin FIG. 6 ) to release the wires one, 112, 114 from the poke-interminals 300 should the need arise. A tool may be inserted into therelease openings 240 to actuate the wire release elements 380.

FIG. 13 illustrates the electrical connector assembly 100 showing thepoke-in wire connector 200 poised for coupling to the cover plate 102.FIG. 14 illustrates the electrical connector assembly 100 showing thepoke-in wire connector 200 coupled to the cover plate 102. Duringassembly, the housing 202 is coupled to the mounting plate 140 of thecover plate 102. The wires 110, 112, 114 are flexible to allow thehousing 202 to position relative to the cover plate 102. Because thestrain relief device 104 is loosely coupled to the power cable 106, thepower cable 106 may be pressed downward through the hub 120 of thestrain relief device 104 as the housing 202 is positioned relative tothe cover plate 102.

During assembly, the mounting tabs 148 are aligned with the pockets 224of the housing 202. The housing 202 is coupled to the cover plate 102 byloading the mounting tabs 148 into the pockets 224. The housing 202 maybe seated against the mounting plate 140. During assembly, the latches226 are latchably coupled to the mounting plate 140. The latches 226secure the housing 202 on the cover plate 102. The latches 226 preventrearward movement of the housing 202 relative to the mounting plate 140.The mounting tabs 148 event forward movement and side to side movementof the housing 202 relative to the mounting plate 140. In an exemplaryembodiment, the housing 202 includes central latches 250 extending fromthe bottom housing wall 212. The central latches 250 are received in aslot 150 between the mounting tabs 148. The central latches 250 securethe housing 202 to the cover plate 102. The central latches 250 preventliftoff of the housing 202 from the cover plate 102.

After the poke-in wire connector 200 is coupled to the cover plate 102,the strain relief device 104 may be fully coupled to the power cable106. For example, the fasteners 128 may be tightened to secure the clamp126 around the conduit 108. When the strain relief device 104 is clampedonto the conduit 108, the conduit 108 and the power cable 106 are fixedrelative to the strain relief device 104, the cover plate 102, and thepoke-in wire connector 200.

FIG. 15 illustrates the electrical connector assembly 100 poised forcoupling to the electrical device 10. FIG. 16 illustrates the electricalconnector assembly 100 partially coupled to the electrical device 10.During assembly, the electrical connector assembly 100 is coupled to thebottom wall 16 of the device housing 14. The poke-in wire connector 200is loaded into the opening 22 of the wall 16 such that the poke-in wireconnector 200 is positioned within the cavity 18 of the device housing14. The poke-in wire connector 200 interfaces with the tab terminals 20within the interior of the device housing 14.

During assembly, the guide pins 230 are aligned with guide openings 26in the bottom wall 16. The guide openings 26 and the guide pins 230properly positioned the poke-in wire connector 200 within the electricaldevice 10. The poke-in wire connector 200 is loaded through the opening22 until the mounting plate 140 of the cover plate 102 is seated againstthe bottom wall 16 of the device housing 14. Once the poke-in wireconnector 200 is loaded through the opening 22, the electrical connectorassembly 100 may be slid forward to mate the poke-in wire connector 200with the tab terminals 20. For example, the tab terminals 20 may bereceived in the cavities 220 of the housing 202 to mate with the poke-interminals 300. The tab terminals 20 are received in the tab terminalssockets 320 of the poke-in terminals 300 as the electrical connectorassembly 100 is slid forward in a mating direction. Once mated, thecover plate 102 may be secured to the bottom wall 16 of the devicehousing 14 using the fastener 24 (shown in FIG. 2 ).

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from its scope. Dimensions, types of materials,orientations of the various components, and the number and positions ofthe various components described herein are intended to defineparameters of certain embodiments, and are by no means limiting and aremerely exemplary embodiments. Many other embodiments and modificationswithin the spirit and scope of the claims will be apparent to those ofskill in the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, in the following claims, theterms “first,” “second,” and “third,” etc. are used merely as labels,and are not intended to impose numerical requirements on their objects.Further, the limitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112(f), unless and until such claim limitations expresslyuse the phrase “means for” followed by a statement of function void offurther structure.

What is claimed is:
 1. A poke-in wire connector comprising: a housingincluding a top housing wall, a bottom housing wall, a first housingside wall, and a second housing side wall, the housing includingterminal cavities extending between a front and a rear of the housing,the housing including separating walls between the terminal cavities;and a plurality of poke-in terminals received in corresponding terminalcavities, each poke-in terminal including a main body extending betweena mating end and a terminating end, a tab terminal socket at the matingend, and a wire socket at the terminating end, the tab terminal socketprovided at the front of the housing for receiving a corresponding tabterminal, the tab terminal socket including a top wall, a bottom wall, afirst side wall, and a second side wall forming a tab terminalreceptacle configured to receive the corresponding tab terminal, the tabterminal receptacle being rectangular shaped, the tab terminal socketincluding upper beam contacts extending from the top wall into the tabterminal receptacle to interface with the tab terminal and lower beamcontacts extending from the bottom wall into the tab terminal receptacleto interface with the tab terminal, the wire socket provided at the rearof the housing for receiving a corresponding wire during a poke-inprocess, the wire socket including a first wall, a second wall, a thirdwall, and a fourth wall forming a wire receptacle configured to receivethe corresponding wire, the wire socket including a first poke-inretention beam configured to interface with the wire when poked into thewire socket and a second poke-in retention beam configured to interfacewith the wire when poked into the wire socket, the wire socket includinga wire release element configured to be actuated to release the firstand second poke-in retention beams from the wire.
 2. The poke-in wireconnector of claim 1, wherein the wire release element is provided alongthe first wall of the wire socket.
 3. The poke-in wire connector ofclaim 1, wherein the wire release element is deflectable into the wirereceptacle to interface with the first and second poke-in retentionbeams.
 4. The poke-in wire connector of claim 1, wherein the wirerelease element includes a main beam extending between a fixed end and afree end, the wire release element including a first deflecting tabextending from the main body of the wire release element at the free endto engage the first poke-in retention beam, the wire release elementincluding a second deflecting tab extending from the main body of thewire release element at the free end to engage the second poke-inretention beam.
 5. The poke-in wire connector of claim 4, wherein thefirst and second deflecting tabs are flared upward nonparallel to themain beam.
 6. The poke-in wire connector of claim 1, wherein the wiresocket includes a front box and a rear box, the first and second poke-inretention beams located between the front box and the rear box, the wirerelease element located between the front box and the rear box.
 7. Thepoke-in wire connector of claim 1, wherein the main body includes a stopfeature forward of the wire receptacle configured to block loading ofthe wire into the wire receptacle to locate the wire in the wirereceptacle.
 8. The poke-in wire connector of claim 1, wherein the mainbody includes a bottom plate generally coplanar with the bottom wall ofthe tab terminal socket.
 9. The poke-in wire connector of claim 1,wherein the tab terminal receptacle has a first height and a firstwidth, the wire receptacle having a second height and a second width,the first width being greater than the second width, the first heightbeing less than the second height.
 10. The poke-in wire connector ofclaim 9, wherein the first width is at least twice the first height, andwherein the second width is approximately equal to the second height.11. The poke-in wire connector of claim 1, wherein the housing includesrelease openings aligned with the wire release elements of the poke-interminals to access the wire release elements from an exterior of thehousing.
 12. The poke-in wire connector of claim 1, wherein the housingincludes is a latch configured to be latchably coupled to a cover plateto secure the housing to the cover plate.
 13. The poke-in wire connectorof claim 1, wherein the housing includes a guide pin to guide mating ofthe housing with a device housing of an electrical device.
 14. Anelectrical connector assembly comprising: a cover plate including amounting flange configured to be mounted to a device housing of anelectrical device, the cover plate including an opening; a strain reliefdevice coupled to the cover plate at the opening of the cover plate, thestrain relief device included a bore therethrough configured to receivea power cable including a plurality of power wires including a groundwire, a hot wire and a neutral wire, the strain relief device providingstrain relief for the power cable; and a poke-in wire connector coupledto the cover plate, the poke-in wire connector including a housinghaving terminal cavities and poke-in terminals received in correspondingterminal cavities, the poke-in terminals configured to be electricallyconnected to the ground wire, the hot wire and the neutral wire, thehousing including a top housing wall, a bottom housing wall, a firsthousing side wall, and a second housing side wall, the terminal cavitiesextending between a front and a rear of the housing, the housingincluding separating walls between the terminal cavities, each poke-interminal including a main body extending between a mating end and aterminating end, a tab terminal socket at the mating end, and a wiresocket at the terminating end, the tab terminal socket provided at thefront of the housing for receiving a corresponding tab terminal of theelectrical device, the tab terminal socket including a top wall, abottom wall, a first side wall, and a second side wall forming a tabterminal receptacle configured to receive the corresponding tabterminal, the tab terminal socket including upper beam contactsextending from the top wall into the tab terminal receptacle tointerface with the tab terminal and lower beam contacts extending fromthe bottom wall into the tab terminal receptacle to interface with thetab terminal, the wire socket provided at the rear of the housing forreceiving a corresponding power wire during a poke-in process, the wiresocket including a first wall, a second wall, a third wall, and a fourthwall forming a wire receptacle configured to receive the correspondingpower wire, the wire socket including a first poke-in retention beamconfigured to interface with the power wire when poked into the wiresocket and a second poke-in retention beam configured to interface withthe power wire when poked into the wire socket, the wire socketincluding a wire release element configured to be actuated to releasethe first and second poke-in retention beams from the power wire. 15.The electrical connector assembly of claim 14, wherein the bore of thestrain relief device receives a conduit surrounding the power cable, thestrain relief device being coupled to the conduit.
 16. The electricalconnector assembly of claim 14, wherein the cover plate includes amounting tab extending therefrom, the housing of the poke-in wireconnector including a pocket receiving the mounting tab of the coverplate, the housing of the poke-in wire connector including a latch belatchably coupled to the cover plate.
 17. The electrical connectorassembly of claim 14, wherein the housing includes release openingsaligned with the wire release elements of the poke-in terminals toaccess the wire release elements from an exterior of the housing. 18.The electrical connector assembly of claim 14, wherein the housingincludes a guide pin to guide mating of the housing with a devicehousing of an electrical device.
 19. The electrical connector assemblyof claim 14, wherein the wire release element is deflectable into thewire receptacle to interface with the first and second poke-in retentionbeams.
 20. The electrical connector assembly of claim 14, wherein thewire release element includes a main beam extending between a fixed endand a free end, the wire release element including a first deflectingtab extending from the main body of the wire release element at the freeend to engage the first poke-in retention beam, the wire release elementincluding a second deflecting tab extending from the main body of thewire release element at the free end to engage the second poke-inretention beam.